Virtual cutting and optimization of three-axis milling processes

This paper presents generalized process simulation and optimization strategies to predict and improve the performance of three-axis milling operations. Cutter-part engagement conditions are extracted from a solid modeling system, which can handle free form part surfaces found in dies and molds. The cutting force distribution along the engaged cutting edge-part surface is evaluated based on the laws of mechanics of milling. By integrating the distributed force along the cutting edge, total forces, torque and power are either predicted analytically using closed-form solutions, or numerically if the cutting tool shape is discontinuous. Simulation results are then used in a constraint-based optimization scheme to maximize the material removal rate (MRR) by calculating acceptable feedrate levels. The proposed virtual milling system is demonstrated experimentally in milling a stamping die with free form surfaces.

[1]  Ismail Lazoglu,et al.  Feedrate scheduling strategies for free-form surfaces , 2006 .

[2]  William H. Press,et al.  Numerical Recipes in FORTRAN - The Art of Scientific Computing, 2nd Edition , 1987 .

[3]  Chia-Hsiang Menq,et al.  Integrated planning for precision machining of complex surfaces. Part 1: Cutting-path and feedrate optimization , 1997 .

[4]  Mohamed A. Elbestawi,et al.  Milling process simulation : A generic solid modeller based paradigm , 1998 .

[5]  N. Tounsi,et al.  Dynamic cutting force measuring , 2000 .

[6]  S. A. Spiewak.  Analytical Modeling of Cutting Point Trajectories in Milling , 1994 .

[7]  Zhijun Wu,et al.  A solid model-based milling process simulation and optimization system integrated with CAD/CAM , 2003 .

[8]  Ismail Lazoglu,et al.  Increasing productivity in sculpture surface machining via off-line piecewise variable feedrate scheduling based on the force system model , 2004 .

[9]  Doruk Sūkrū Merdol,et al.  Virtual three-axis milling process simulation and optimization , 2008 .

[10]  Yusuf Altintas,et al.  A Solid Modeller Based Milling Process Simulation and Planning System , 1994 .

[11]  Yusuf Altintas,et al.  Mechanics and dynamics of general milling cutters.: Part I: helical end mills , 2001 .

[12]  E. Eleftheriou,et al.  Analysis of the Mechanics of Machining with Tapered End Milling Cutters , 1994 .

[13]  Jeffrey G. Hemmett,et al.  Robust Feedrate Selection for 3-Axis NC Machining Using Discrete Models , 2001 .

[14]  John W. Sutherland,et al.  An Improved Method for Cutting Force and Surface Error Prediction in Flexible End Milling Systems , 1986 .

[15]  Richard E. DeVor,et al.  MECHANISTIC MODEL FOR THE PREDICTION OF THE FORCE SYSTEM IN FACE MILLING OPERATIONS. , 1984 .

[16]  A. Lamikiz,et al.  Cutting force estimation in sculptured surface milling , 2004 .

[17]  Taylan Altan,et al.  Feed rate optimization based on cutting force calculations in 3-axis milling of dies and molds with sculptured surfaces , 1994 .

[18]  Yusuf Altintas,et al.  End Milling Force Algorithms for CAD Systems , 1991 .

[19]  Klaus Weinert,et al.  Milling Simulation for Process Optimization in the Field of Die and Mould Manufacturing , 1997 .

[20]  Dong-Woo Cho,et al.  Off-line feed rate scheduling using virtual CNC based on an evaluation of cutting performance , 2003, Comput. Aided Des..

[21]  L. A. Kendall,et al.  An analytic mechanistic cutting force model for milling operations: a theory and methodology , 1994 .

[22]  T. I. El-Wardany,et al.  Generic Simulation Approach for Multi-Axis Machining, Part 2: Model Calibration and Feed Rate Scheduling , 2002 .

[23]  Yusuf Altintas,et al.  Prediction of Ball End Milling Forces , 1996 .

[24]  Hsi-Yung Feng,et al.  Integrated tool path and feed rate optimization for the finishing machining of 3D plane surfaces , 2000 .

[25]  W. P. Wang,et al.  Solid modeling for optimizing metal removal of three-dimensional NC end milling , 1988 .

[26]  Steven Y. Liang,et al.  ANALYTICAL MODELING OF FORCE SYSTEM IN BALL-END MILLING , 1997 .

[27]  Erhan Budak,et al.  Maximizing Chatter Free Material Removal Rate in Milling through Optimal Selection of Axial and Radial Depth of Cut Pairs , 2005 .

[28]  Yusuf Altintas,et al.  Mechanism of Cutting Force and Surface Generation in Dynamic Milling , 1991 .

[29]  Yusuf Altintas,et al.  Mechanics and Dynamics of Ball End Milling , 1998 .